News and articles from Topstar

For today’s manufacturers, balancing productivity, quality, and sustainability is crucial. Traditional hydraulic injection molding machines, while reliable, consume a significant amount of energy; all-electric injection molding machines solve the energy problem, but have high initial costs and limited flexibility in heavy-duty applications. A hybrid injection molding machine combines the best of both worlds, integrating the… Continue reading Guide to Hybrid Injection Molding Machine: Servo-Hydraulic Synergy for 40% Energy Savings

Poor plasticization in the injection molding process can lead to bubbles, uneven surfaces, or brittle edges on parts, making them unsuitable for quality inspection. This not only wastes raw materials but also consumes time and increases labor costs. The main problem lies in poor management during the pre-plasticization stage; unstable pressure or temperature can cause… Continue reading How to Solve Poor Plasticization in the Injection Molding Process？

Inefficient injection molding operations are often caused by delays between steps, resulting in lower overall efficiency. For example, a slow-responding dryer causes the molding machine to be idle; drifting mold temperature controllers result in scrap. As a result, operators waste two hours a day switching between five different control interfaces. This lack of equipment coordination… Continue reading How to solve the problem of low production efficiency: Topstar’s molding machine to improve overall efficiency by 15%

A car interior parts manufacturer was struggling with problems with cold-runner injection molds. Their products suffered from defects such as shrinkage marks, short shots, and uneven wall thickness, all stemming from “low-temperature dead zones” in the runner system, where the temperature is 15-20 degrees Fahrenheit below the set value. Their traditional on/off mold temperature controllers… Continue reading Guide to PID control Mold temperature controller: Fix Low-Temperature Dead Zones in Cold Runner Injection Molding

A consumer electronics miniature connector manufacturer found that their existing hydraulic injection molding machine couldn’t generate enough stable ejection force to eject high-precision USB-C connectors smoothly. 12% of their monthly production was scrap—parts stuck in the mold, pins bent, shells cracked—due to either a malfunctioning ejection mechanism or excessive ejection force. Clearly, this was due… Continue reading Servo-driven injection molding machine for easier connector demolding: 20% increase in ejector thrust

With the widespread adoption of digitalisation across various manufacturing sectors, many injection moulding plants are striving to maintain competitiveness, driving an increasing demand for intelligent injection moulding machines. By integrating intelligent technologies such as the Internet of Things (IoT), artificial intelligence (AI), and injection moulding machine learning, these machines not only improve production efficiency but… Continue reading The Importance of Intelligent Digitalization in the Future Development of Injection Moulding Machines

Low cavity fill rate is a significant challenge in high-speed injection molding. For products such as thin-walled containers, caps, or blister packaging, even a cycle time reduced to 3-5 seconds can lead to a 5% decrease in output and a 20% increase in scrap costs. The primary reason for this is the mismatch between injection… Continue reading Solving the problem of low cavity filling rate in high-speed packaging injection molding

The screw in an injection mold machine primarily functions to melt, mix, and precisely inject plastic. Choosing the wrong screw can lead to scrap, delays, and material waste. Selecting the right screw ensures consistent quality and lower costs. The choice between a single-screw and a twin-screw injection mold boils down to one question: what material… Continue reading Injection Mold Machine Screw Selection Guide: Single Screw vs. Twin Screw Selection

Precision plastic parts, such as medical components, automotive sensors, or electronic housings, require extremely high consistency. Even a deviation of 0.01 mm can render a part unusable. Hydraulic injection molding machines, due to their fluid-driven motion, struggle with pressure fluctuations, leading to uneven clamping and slow response times, which in turn cause injection instability. All-electric… Continue reading Guide to All-Electric Injection Molding Machine for Precision Plastic Parts: 90T-200T TEII Series

The cooling system in injection molding is a crucial element for stable performance. The water tank capacity of the water chiller is more than just a number; it determines the balance between heat dissipation and machine requirements. Insufficient capacity leads to warping and slow production cycles; excessive capacity results in wasted energy and upfront costs.… Continue reading How to Select Water Chiller Tank Capacity: Fit Injection Molding Machine Cooling Demand

A customer told us they were using a 220-ton injection molding machine to produce 10mm thick electric vehicle battery casings, but 27% of the parts were defective: some had flash (thin plastic seeping from between the mold halves), and some were severely deformed and failed quality inspection. To prevent flash, they increased the clamping force… Continue reading How to Adjust Clamping Force on a 220-ton injection molding machine for Thick-Wall Plastic Parts？

When the mold opening position of a plastic injection molding machine deviates by 3 mm per cycle, it causes flash (excess plastic) on precision parts, rendering them unusable. In industries such as medical, automotive, or electronics, part tolerances can be as small as ±0.5 mm, and even a 1 mm deviation can have serious consequences.… Continue reading How to solve the accuracy deviation of the mold opening position in a plastic injection molding machine?